JP2024502227A - Chenille carpet and its manufacturing method - Google Patents

Abstract

A chenille carpet and a manufacturing method thereof, the manufacturing method includes step S1: tufting a base fabric layer (2) using chenille yarn, and then applying a carpet surface layer (1) on one side of the base fabric layer (2). ) to obtain a blank carpet; S2, putting the blank carpet from step S1 into a forming roll machine, heating and rolling it, inverting it, subjecting it to steam softening treatment, and lowering its temperature by natural cooling; S3 , performing a bottom coating process on the carpet obtained in step S2. This manufacturing method uses less water, consumes less energy, saves time, is environmentally friendly, and the resulting chenille carpet has high bulk and fullness. [Selection diagram] Figure 1

Description

TECHNICAL FIELD The present invention relates to the field of spinning, and specifically to a chenille carpet and its manufacturing method.

Chenille yarn is made by using two twisted wires as core threads, and by twisting them, it is woven with a filament sandwiched between them. Chenille yarn has the characteristics of puffy feathers, soft touch, thick and lightweight fabric, and is widely used in the home textile field. Chenille yarn can be combined with tufting and knitting processes to create various types of yarn. Carpets are created to enrich people's home experience.

The general manufacturing process route for currently commercially available chenille carpets is: spinning - weaving on a tufting or knit circular knitting machine - falling water dyeing process - dehydration - drying and shaping - applying adhesive on the back side (composite) - cutting - sewing. This process involves manufacturing a blank carpet by combining the yarn obtained by spinning as a first layer with a second layer of base fabric using a tufting method, and then dyeing this blank carpet using a rapid dyeing machine or a jigger dyeing machine, etc. Blank carpets with various colors are produced by dyeing them in a dyeing machine for about 100 minutes based on the required color shading.Furthermore, the blank carpets are placed in a dehydrator and dehydrated for about 20 minutes, and then dried in a relaxing dryer. Finally, the carpet is manufactured by cutting and sewing. Chinese patent CN101139788A discloses a shiny chenille carpet fabric and manufacturing process, which includes the steps of manufacturing chenille yarn - weaving chenille yarn into chenille carpet fabric - dyeing process - finishing - dehydration - drying shaping, and this patent The production process route is long, and the cost and energy consumption are high.

Conventionally, in the manufacturing process of general-purpose chenille carpet, it is necessary to use a large amount of water as a dye carrier in the dyeing process to produce various colors by combining with the yarn fiber molecules or entering the gaps between the fiber molecules. , Take dyeing chenille carpet with a rapid dyeing machine as an example, the bath ratio used is 1:10, that is, in order to dye 200 kg of chenille carpet, it is necessary to produce the dyeing solution with 2000 kg of water, and the dyeing factory Although it is possible to purify and recycle water resources within the country, a large amount of water loss will result in huge waste, and large amounts of chemicals are used in wastewater treatment, and large amounts of chemical substances remain, which is harmful to the environment. bring pollution. The dyeing process requires a huge amount of thermal energy to ensure the smooth progress of the dyeing process, and in a typical dyeing process, room temperature water is heated to 70 to 80 degrees Celsius at a heating rate of 2 degrees Celsius/min. Then, the temperature is raised to 100 to 130 °C at a heating rate of 1 °C/min, followed by a heat retention operation for 20 to 30 minutes, and finally a temperature lowering treatment, and the blank carpet after dyeing is further dehydrated and dried. The whole process takes a long time, consumes a lot of energy, and has a huge water usage. There is also chenille, which is made from yarn-dyed yarn, which undergoes a water drop treatment, and the other processes are the same as above except that no dye is used, and a large amount of waste water and chemical residue is also generated. In the manufacturing process of the current commercial chenille carpet, 0.8g/L of leveler, the corresponding blending ratio of dye and 1% to 3% of softener and reducing detergent are added, and the resulting product is soft to the touch. However, the addition of chemical auxiliaries causes some damage to the environment. For example, Chinese patent CN108301244A discloses a method for producing ultra-super absorbent short-haired chenille mat, including the step of dyeing the mat substrate, pre-treatment soaking before dyeing, and polyester mat substrate before use. The dyed body is added, first immersed in soft water, pre-soaked, and heated in a preheating steam room at 60°C at room temperature to 90°C every 2°C/min until the temperature reaches around 90°C. After stabilization, steam for 10 minutes, heat up to 110°C at -1°C/min, steam for 10 minutes, cool down to 60°C at 3°C/min, then take out and place in a self-staining machine for dyeing. Make preparations. Components of dye ink include disperse dyes, levelers, softeners, lubricants, processing agents, and the like. Such dyeing processes are time-consuming, energy-intensive, water-intensive, and chemical auxiliaries are environmentally damaging.

In addition, the chenille carpets currently on the market have a high degree of pile shrinkage, the pile fibers are tightly arranged, the fibers are straight, the bulk and swelling of the pile is insufficient, and the water absorption ability is poor. The inventor's prior patent CN104783632A discloses a processing method to imitate Indian artificial chenille mat, which sequentially includes the following processing steps: dyeing of chenille yarn → treatment of chenille base fabric → tufting → anti-slip organization → locking treatment. The chenille carpet produced in this patent has a loop pile shape, and has undesirable bulkiness, swelling, and water absorption.

Therefore, in order to overcome the problems existing in the prior art, which are time-consuming, high energy consumption, high water consumption, polluting the environment, and poor bulkiness, methods for producing chenille carpets are currently being developed. This has become an urgent task.

In order to solve the above technical problems, the present invention provides a chenille carpet and a method for manufacturing the same.

The object of the invention is achieved by the following technical aspects.

A composite base fabric layer composed of a carpet surface layer, a base fabric layer, and a bottom lining layer, wherein the base fabric layer is formed of a synthetic fiber knit or fabric fabric base layer, a synthetic fiber knit or fabric fabric, and/or a needle-punched synthetic fiber nonwoven fabric, or a spunbond nonwoven fabric base layer, wherein the carpet surface layer includes a loop pile tufting layer formed on one side of the base layer after tufting the base layer using chenille yarn; The backing layer includes an anti-slip treatment layer that is a composite of hot melt adhesive, thermoplastic elastomer, foamed latex or other fabrics and materials with an anti-slip function, and is heated and rolled in a forming roll machine and subjected to steam softening treatment, A chenille carpet that is cooled and cooled to form a loop pile in the tufted layer into a granular pile.
Preferably, the height of the loop pile of the tufting layer is 3.5 mm to 45 mm.

Preferably, the type of base fabric layer includes the following:
The composite base fabric layer is a needle-punched synthetic fiber nonwoven fabric, and its weight is 50 to 500 g/ ^m2 , and the composite base fabric layer is a synthetic fiber knit or cloth fabric, and its weight is 70 to 350 g/ ^m2 . ,
The weight of the knit or fabric base layer is 50 to 350 g/m ² ,
The weight of the spunbond nonwoven fabric base layer is 50 to 350 g/m ² .

Preferably, the raw material of the base fabric layer may be one or more of chemical fibers, natural fibers, and blended fibers.

Preferably, the chenille yarn of the carpet surface layer is a novel design yarn, which has two strands woven with short fibers or filaments of different finenesses as core yarns, and is twisted at different twist degrees to create different finenesses. It is made by cutting the filaments into different widths and sandwiching them between two core threads for weaving.

Preferably, the material of the chenille yarn of the carpet surface layer is one or more of fibers such as polyester, nylon, cotton, or blended fibers,
Preferably, the chenille yarn count of the carpet surface layer is 2.6 Nm to 0.2 Nm,
Preferably, the chenille yarn of the carpet surface layer has a twist of 280 T/M to 800 T/M,
Preferably, the filament count of the snow yarn of the carpet surface layer is 30D to 600D,
Preferably, the filament width of the chenille yarn of the carpet surface layer is between 2 mm and 15 mm.

The present invention
S1: After performing a tufting process on the base fabric layer using chenille yarn, a carpet surface layer is formed on one side of the base fabric layer to obtain a blank carpet; The step of heating, rolling, inverting, subjecting to steam softening treatment, and lowering the temperature by natural cooling;
S3. The carpet obtained in step S2 is subjected to bottom coating, that is, the bottom of the carpet is coated with hot melt adhesive, thermoplastic elastomer, foam adhesive, or other single backing material or anti-slip treatment. The method of manufacturing the chenille carpet includes the step of:

Preferably, the type of forming roll machine in step S2 includes a steam-type forming roll machine, an electrically heated/thermal conductive oil-type forming roll machine, or a natural gas-heated oil-type forming roll machine,
Preferably, in step S2, the forming roll machine has a built-in rolling housing, which is similar to the structure of a household drum washing machine, and in the process of step S2, the rolling housing is built-in for effective propagation and uniform dispersion of the heat quantity. Multiple heat radiation holes are distributed in the housing of the housing,
Preferably, the built-in rolling housing of the forming roll machine in step S2 can be set for forward and reverse rotation, and the rotation speed can be set for constant speed or frequency conversion control as necessary, and the rolling speed The variable range is 10r/min to 30r/min, and the forward/reverse rotation time can be set as required.The rotation time is 5min to 120min, and the forward/reverse direction is automatically cycled uniformly. can be switched,
Preferably, in step S2, the blank carpet is in a naturally loosened state in the casing of the forming roll machine, and in the process of the blank carpet rotating with the built-in casing of the forming roll machine, the blank carpet is loosened on the inner wall of the casing. Cycle and repeat, so that after reaching a certain height, it falls freely and starts the next rotation,
Preferably, in step S2, the temperature setting range in the heating rolling process of the forming roll machine is 70°C to 200°C,
Preferably, the time for the steam softening treatment in step S2 is 5 s to 600 s,
Preferably, in step S2, the heating program is turned off during the temperature-lowering process due to natural cooling, the blower naturally lowers the temperature of the blank carpet through internal circulation, and during the temperature-lowering process, the built-in casing of the forming roll machine is turned off during the temperature-lowering process. Until the end, it still operates to automatically cycle and switch the rotation direction evenly,
Preferably, all operations in step S2 can be performed manually or by an automatic program to realize continuous operation.

Alternatively, step S2 of the chenille carpet manufacturing method of the present invention is
S2: Put the blank carpet from step S1 into a shaker dryer, blow it with the blower of the dryer, use the wind force to advance the blank carpet into the S-shaped air path inside the dryer, and shake and heat dry the carpet with the dryer. It may also be a step of performing high frequency friction between the blank carpet and the S-shaped air path while shaking the carpet.

Preferably, the type of shaker drying machine in step S2 includes a steam type shaker drying machine, an electric heating/thermal conduction oil type shaker drying machine, and a natural gas heating oil type shaker drying machine,
Preferably, in step S2, the shaker drying machine has two or more powerful blowers, the motor power of the blower is 20KW to 40KW, and the rotation speed of the blower is 100r/min to 1500r/min,
Preferably, in step S2, in the shaker drying machine, a blower blows to form wind power to further advance the blank carpet into the machine, and the blower is a power source for conveying the blank carpet,
Preferably, the first half of the shaker drying machine in step S2 is an S-shaped curved wind duct unit, and the second half is a mesh belt type conveying unit, the first half serves as a power source, and the second half serves as a conveying, Playing the role of a guide, the shaker drying shaping machine transports the carpet by wind power, and due to the strong wind and the S-shaped curved structure of the duct, the carpet substrate in S1 forms a shake state, and the S-shaped duct structure forms a shake state between it and the blank carpet. A frictional state is formed at
Preferably, the temperature control range of the shaker drying machine in step S2 is 100°C to 200°C,
Preferably, the operating speed of the shaker dryer in step S2 is 0.5 m/min to 10 m/min.

Alternatively, step S2 of the chenille carpet manufacturing method of the present invention is
S2 may be a step of putting the blank carpet of step S1 into a steam dryer and heating and rolling the blank carpet to dry it.
Preferably, the external shape and internal structure of the steam dryer in step S2 are similar to those of a large industrial washing machine, including a built-in drum and a plurality of heat radiation holes distributed on the drum wall.
Preferably, in step S2, the pile weight of the blank carpet that can be accommodated in the steam dryer is 15KG to 250KG,
Preferably, the rotation speed of the drum of the steam dryer in step S2 is 29 r/min to 35 r/min,
Preferably, the heating temperature of the steam dryer in step S2 is 70°C to 180°C.

Alternatively, step S2 of the chenille carpet manufacturing method of the present invention is
S2 may be a step in which the blank carpet from step S1 is placed in a built-in drum of a GQ-3500Z steam forming roll machine and subjected to high temperature friction and forming roll treatment.

In addition, after step S2 is completed, a process of spraying a softener onto the carpet surface can be carried out according to usage needs. The amount of hydraulic fluid used is 50g/m2-200g/ ^m2 .

Furthermore, the chenille carpet obtained by the present invention can be used for secondary processing such as textile printing to obtain new products.

The present invention has the following beneficial effects.
The carpet of the present invention does not require the consumption of large amounts of water resources during the manufacturing process, and does not use a dyeing tank during the manufacturing process. It does not use chemical auxiliaries such as dyes and smoothing agents to avoid environmental pollution, and the carpet manufacturing process has a short process path and does not need to consume large amounts of energy, and the blank carpet of the carpet is put into the forming roll machine. As a result, the blank carpet rotates with the built-in drum of the forming roll machine and undergoes high-temperature friction, causing the chenille filament fibers to contract, swell, and deform, and the core yarn undergoes high-temperature friction contraction to form the blank carpet pile. The fibers are shrunk from a loop pile shape and self-twisted into particles, and the core yarn exhibits a natural crimp state after high-temperature friction shrinkage, thereby increasing the bulkiness and swelling of the carpet surface layer of the carpet.

FIG. 1 is a schematic diagram of the structure of a chenille carpet of the present invention. FIG. 1 is a schematic diagram of a chenille carpet manufactured using a general-purpose process technology. FIG. 2 is a schematic diagram of the structure of a chenille carpet of a prior invention by the present inventor. 1: Carpet surface layer, 2: Base fabric layer, 3: Bottom lining layer.

Hereinafter, the present invention will be described in detail with reference to Examples. The following examples will help those skilled in the art to further understand the invention, but are not intended to limit the invention in any way. It should be noted that those skilled in the art can make some adjustments and improvements without departing from the idea of the present invention, all of which fall within the protection scope of the present invention.

The present invention provides a chenille carpet and a method of manufacturing the same.

The chenille carpet includes a carpet surface layer, a base fabric layer, and a bottom lining layer, and the base fabric layer includes a synthetic fiber knit or fabric base fabric layer, a composite base formed of a synthetic fiber knit or fabric fabric, and/or a needle-punched synthetic fiber nonwoven fabric. The carpet surface layer is a cloth layer or a spunbond nonwoven fabric base layer, and the carpet surface layer includes a loop pile tufting layer formed on one side of the base fabric layer after tufting the base fabric layer using chenille yarn. Further, a carpet surface layer having a particulate form is formed by processing, and specifically, it may be a carpet surface layer having a particulate pile formed through vibration, shaking, and friction at a constant temperature. The bottom lining layer includes an anti-slip treatment layer that is a composite of hot melt adhesive, thermoplastic elastomer, foamed latex or other fabrics and materials with anti-slip function, and is heated and rolled in a forming roll machine and subjected to steam softening treatment. The tufted layer is then cooled and the temperature is lowered to form a loop pile of the tufted layer into a granular pile. Note that the temperature lowering method may be a temperature lowering method by natural cooling, a strong cooling temperature lowering method, or another feasible temperature lowering method.

The method for manufacturing the chenille carpet includes the following steps.

A. Regarding yarn spinning, take dyed yarn or cotton yarn to make filament yarn, use ordinary polyester short fibers or cotton yarn as core yarn to manufacture chenille yarn, and manufacture packages using a winder.
B. Regarding the creation of the base fabric layer, select the base fabric and create the base fabric layer, and the base fabric is one of the following: fabric base fabric, spunbond nonwoven fabric base fabric, polyester short fiber and polypropylene fabric composite base fabric, etc. or containing multiple species;
C. Regarding weaving, the chenille yarn obtained in Step A is hung on the creel of a tufting machine, and using the base fabric layer in Step B, it is woven with a tufting machine/circular knitting machine of various pitches to form a loop pile. Obtain a blank carpet of
D. Regarding forming roll processing, the blank carpet obtained in step C is put into a forming roll machine and processed through the flow of drying-steam softening treatment-residual heat cooling and temperature-lowering treatment, or by processing with a fixed-forming machine to form a blank carpet. to form the loop pile of the carpet surface layer into a granular pile,
E. Regarding adhesive application on the back side and bottom coating, bottom coating processing is performed on the woven loop pile chenille blank carpet, that is, hot melt adhesive, thermoplastic elastomer, or foam adhesive is used on the bottom of the carpet. or other single backing material or composite backing material with anti-slip treatment function,
F. Regarding the cutting process, the carpet obtained in step E is cut according to the size request,
G. Regarding the sewing process, the carpet cut in step F is hemmed or over-stitched using an hemming machine.

For specific application examples, refer to the following embodiments.

Example 1

This embodiment provides a chenille carpet and its manufacturing method, the manufacturing steps of which are as follows.
S1. Regarding yarn control, a yarn-dyed chenille yarn with a core yarn of polyester 16S/2, a filament yarn of 150D/144FDTY, a twist of 530T/M, and a filament width of 11 mm was selected, and chenille yarn was selected. The yarn count is 0.45Nm,
S2. Regarding the production of the base fabric layer, a polyester filament fabric base fabric was selected, the basis weight of the base fabric was 270 g/ ^m2 , the number of threads was 23.2 x 15.3/cm, and the count was 300D/m2. 96FX3,
S3, for weaving, select a loop pile tufting machine with a pitch of 3/8, set the pile height to 15 mm, set the pile weight of the blank carpet to 850 g/ ^m2 , and set the weaving machine to 270 g/m2 in step ^S2 . Tufting is performed using the base fabric layer,
S4, Regarding forming roll processing, take 50 kg of the tufted blank carpet obtained in step S3, put it into the built-in drum of a GQ-3500Z steam type forming roll machine, and set the rotation speed of the built-in drum of the forming roll machine to 18 r/min. The heating temperature of the forming roll machine was 100°C, the heating rolling time was 7 minutes, the forward and reverse rotation times were 3.5 minutes each, steam softening treatment was performed, the steam temperature was 100°C, and the steam release time was 20 seconds. Then, the water vapor and heating module were turned off, and the temperature was lowered to 70℃ by natural cooling. The cooling time was 5 min. During the entire process, the blank carpet was in a state of natural loosening in the built-in drum of the forming roll machine, and no external force was applied. Then, the blank carpet after the forming roll treatment is taken out,
S5: Applying adhesive to the back side and covering the bottom part: After step S4, the carpet is treated to prevent slipping on the bottom side, and the bottom back side of the carpet is coated using SEBS hot melt adhesive with product number 1135-B. tumbler coated, the amount of adhesive was 40g/ ^m2 ,
S6. Regarding the cutting process, cut the carpet after applying adhesive on the back side according to the required size,
S7. Regarding the sewing process, the cut carpet is hemmed using an edging machine. The hemming cloth is a raised polyester fabric, the weight is 120 g/m ² , and the width of the hemming cloth is 48 mm.

Example 2

This embodiment provides a chenille carpet and its manufacturing method, the manufacturing steps of which are as follows.
S1, regarding yarn spinning, the core yarn is polyester 15S/2, the filament is 150D/288FDTY, the twist is 540T/M, the filament width is 8mm, and the chenille yarn count is 0.7Nm. can be,
S2. Regarding the production of the base fabric layer, a polyester filament fabric base fabric was selected, the basis weight of the base fabric was 130 g/ ^m2 , the number of threads was 42 x 27/inch, and the count was 300D/96F.
S3, for weaving, select a loop pile tufting machine with a pitch of 3/8, set the pile height to 30 mm, set the pile weight of the carpet to 1350 g/ ^m2 , and set the base of 130 g/ ^m2 in step S2. Tufting is performed using a fabric layer,
S4, regarding forming roll processing, take 50 kg of the tufted blank carpet obtained in step S3, put it into the built-in drum of a GQ-3500Z steam type forming roll machine, and set the rotation speed of the built-in drum of the forming roll machine to 18 r/min, The heating temperature of the forming roll machine was 100°C, the heating rolling time was 15 minutes, the forward and reverse rotation times were 7.5 minutes each, and steam softening was performed, the steam temperature was 105°C, and the steam release time was 30 seconds. The steam and heating module were turned off, and the temperature was lowered to 70℃ by natural cooling, and the cooling time was 8 min. During the entire process, the blank carpet was in a state of natural loosening in the built-in drum of the forming roll machine. Without being constrained by external forces, the blank carpet after the forming roll treatment is subsequently taken out,
S5: Applying adhesive to the back side and covering the bottom part: After step S4, the carpet is treated to prevent slipping on the bottom side, and the bottom back side of the carpet is coated using SEBS hot melt adhesive with product number 1135-B. tumbler coated, the amount of adhesive was 40g/m2,
S6. Regarding the cutting process, cut the carpet after applying adhesive on the back side according to the required size,
S7. Regarding the sewing process, the cut carpet is hemmed using an edging machine. The hemming cloth is a raised polyester fabric, the weight is 120 g/m ² , and the width of the hemming cloth is 48 mm.

Example 3

This embodiment provides a chenille carpet and its manufacturing method, the manufacturing steps of which are as follows.
S1, regarding yarn spinning, the filament is 150D/192FDTY, the twist is 550T/M, the filament width is 7mm, the core yarn is polyester 20S/2, and the chenille yarn count is 1.5Nm. can be,
S2. Regarding the production of the base fabric layer, a polyester filament fabric base fabric was selected, the basis weight of the base fabric was 180 g/ ^m2 , the number of threads was 86.5 x 41/inch, and the count was 300D/96F. can be,
S3, for weaving, select a loop pile tufting machine with a pitch of 1/8, set the pile height to 20 mm, set the pile weight of the carpet to 700 g/ ^m2 , and set the base of 180 g/ ^m2 in step S2. Tufting is performed using a fabric layer,
S4. Regarding forming roll processing, take 50 kg of the tufted blank carpet obtained in step S3 and put it into the built-in drum of a GQ-3500Z steam type forming roll machine, and set the rotation speed of the built-in drum of the forming roll machine to 20 r/min. The heating temperature of the forming roll machine was 105°C, the heating rolling time was 10 minutes, the forward and reverse rotation times were 5 minutes each, steam softening was performed, the steam temperature was 103°C, and the steam release time was 15 seconds. , the water vapor and the heating module are turned off, and the temperature is lowered to 70℃ by natural cooling, and the cooling time is 7 min. During the whole process, the blank carpet is in a state of natural loosening in the built-in drum of the forming roll machine, and no external force is applied. Unrestricted, the blank carpet after the forming roll treatment was subsequently taken out,
S5: Applying adhesive to the back surface and covering the bottom surface After step S4, the carpet was treated with anti-slip treatment on the back surface of the bottom surface, and treated with foamed natural latex to prevent slipping, and the basis weight of the foamed natural latex was 600 g/m. ² ,
S6. Regarding the cutting process, cut the carpet after applying adhesive on the back side according to the required size,
S7. Regarding the sewing process, the cut carpet is hemmed using an edging machine. The hemming cloth is a raised polyester fabric, the weight is 120 g/m ² , and the width of the hemming cloth is 48 mm.

In actual application, the chenille carpet according to this embodiment only includes a base fabric layer and a carpet surface layer, and the materials and manufacturing methods of the carpet surface layer and the base fabric layer are as described above. Chenille carpets are used in combination with other non-slip mats. Examples 4 and 5 describe embodiments of chenille carpets consisting of a base layer and a carpet face layer.

Example 4

This embodiment provides a chenille carpet and its manufacturing method, the manufacturing steps of which are as follows.
S1, regarding yarn spinning, the core yarn is polyester 15S/2, the filament is 150D/288FDTY, the twist is 400T/M, the width of the filament is 15mm,
S2. Regarding the production of the base fabric layer, a spunbond nonwoven base fabric was selected, and the basis weight of the base fabric was 180 g/ ^m2 ,
S3, for weaving, select a loop pile tufting machine with a pitch of 3/8, set the pile height to 15 mm, set the pile weight of the carpet to 850 g/ ^m2 , and set the base of 180 g/ ^m2 in step S2. Tufting is performed using a fabric layer,
S4, for forming roll processing, take 100 ^m2 of the tufted blank carpet obtained in step S3 and put it into a shaker drying shaping machine, the first half of the shaker drying shaping machine is an S-type curved wind duct unit, and the second half is It is a mesh belt type conveyor unit, the first half serves as a power source, and the second half serves as a conveyor and guide.The shaker dryer uses wind power to convey the blank carpet, and also handles strong winds and S-shaped curvature of the duct. Due to the structure, the carpet substrate in S1 forms a shake state, and the S-shaped duct structure forms a friction state with the carpet, causing the loop pile of the carpet surface layer to form a granular pile, and the temperature control range is 100°C, the operating speed is 0.5 m/min,
S5: Regarding the cutting process, the carpet manufactured in S4 is cut according to the required size,
S6. Regarding the sewing process, the cut carpet is hemmed using an edging machine, and the hemming cloth is polyester raised fabric, the weight is 120 g/m ² , and the width of the hemming cloth is 48 mm.

Example 5

This embodiment provides a chenille carpet and its manufacturing method, the manufacturing steps of which are as follows.
S1, regarding yarn spinning, the core yarn is polyester 15S/2, the filament is 150D/288FDTY, the twist is 400T/M, the width of the filament is 15mm,
S2. Regarding the production of the base fabric layer, a composite base fabric layer formed of fabric was selected, and the basis weight of the base fabric layer was 250 g/ ^m2 ,
S3, for weaving, select a loop pile tufting machine with a pitch of 3/8, set the pile height to 20 mm, set the pile weight of the carpet to 1050 g/ ^m2 , and set the base of 250 g/ ^m2 in step S2. Tufting is performed using a fabric layer,
S4, Regarding forming roll processing, take the tufted blank carpet obtained in step S3 at 100 kg and put it into the built-in drum of GQ-3500D electric heating/thermal conduction oil type forming roll machine, and increase the rotation speed of the built-in drum of the forming roll machine. was set at 20 r/min, the heating temperature of the forming roll machine was set at 190°C, the heating rolling time was set at 5 minutes, the steam softening treatment was performed, the temperature of the steam was set at 103°C, and the steam release time was 300 s. The heating module was turned off, and the temperature was lowered to 70℃ by natural cooling, and the cooling time was 7 min. During the entire process, the blank carpet was in a state of being naturally loosened in the built-in drum of the forming roll machine, and was not subject to the constraints of external force. Next, take out the blank carpet after the forming roll treatment,
S5: Regarding the cutting process, the carpet manufactured in S4 is cut according to the required size,
S6. Regarding the sewing process, the cut carpet is hemmed using an edging machine, and the hemming cloth is polyester raised fabric, the weight is 120 g/m ² , and the width of the hemming cloth is 48 mm.

performance test

A. Comparative test of water absorption dropping method

Drop diffusion time mainly reflects the absorption rate of the fabric for moisture, and verifies the quality of water absorption.Water droplets are dropped onto the sample surface from a certain height, and the reflected light on the sample is measured after the droplets come into contact with the sample. Record the time until it disappears. For comparison with the chenille carpet of Example 2, a chenille carpet made by a general process, also weighing 30 g and having the same seams of 11 stitches/10 mm, was dropped in a 20 mL meter glass at the same height of 20 mm. The test was conducted.

The test results show that the disappearance time of the reflected light of the chenille fabric manufactured by conventional general-purpose processes is 1 second, and the disappearance time of the reflected light of the chenille carpet of the present invention is 0.7 seconds. The water absorbency of the chenille carpet of the present invention is higher than that of chenille carpets manufactured by conventional general-purpose processes.

B. Comparative test of bulkiness

The premise of the bulkiness comparison test is to obtain the same type of blank carpet by weaving the same type of chenille yarn and the same type of tufting process.

Regarding the requirements for the bulkiness comparative test,
1. Within the same size range, the number of piles on the carpet surface of the chenille carpet manufactured by the conventional general-purpose process and the chenille carpet of the present invention. 2. Within the same size range, the chenille carpet manufactured by the conventional general-purpose process and the chenille carpet of the present invention. Chenille carpet pile size includes length, width, and height.
The weaving process of the sample is consistent with Example 1, 0.45 Nm chenille yarn is selected, the tufting pitch is 3/8, the tufting pile height is 15 mm, and the tufting seam is 9. The needle is 10 cm, and the base fabric is also 270 g/m ² of polyester filament fabric,
The chenille carpet of Example 1 of the present invention and the chenille carpet manufactured using a conventional general-purpose process were taken. Both sizes were 15 cm x 15 cm. Three samples were taken from each of the carpets manufactured using two types of processes and compared. conduct a test,
The test data is as follows.
The number of piles on the carpet surface of chenille carpets manufactured using conventional general-purpose processes is 360 for sample 1, 360 for sample 2, and 345 for sample 3.
Regarding the number of piles on the carpet surface of the chenille carpet of the present invention, Sample 1 has 270 piles, Sample 2 has 255 piles, and Sample 3 has 270 piles.

As can be seen from the above test data, the number of piles on the carpet surface of the chenille carpet of the present invention is smaller than the number of piles of the chenille carpet manufactured by conventional general-purpose processes. The shrinkage was smaller than the degree of shrinkage of the chenille carpet manufactured by the general-purpose process, indicating that the bulkiness of the chenille carpet of the present invention was superior to that of the carpet manufactured by the general-purpose process.
The chenille carpet of Example 1 of the present invention and the chenille carpet obtained by the conventional general-purpose process were taken, and the sizes of both were 20 cm x 20 cm. Three samples were taken from each of the carpets manufactured by the two types of processes and compared. Conduct the test.

The test data is as follows.
The pile sizes of the carpet surface of chenille carpets manufactured using conventional general-purpose processes are as follows.
Regarding the size of the sampled pile 1, the length is 7 mm, the width is 7 mm, and the height is 12 mm,
Regarding the size of the sampled pile 2, the length is 7 mm, the width is 6.5 mm, and the height is 12.5 mm,
Regarding the size of the sampled pile 3, the length is 6.5 mm, the width is 6.5 mm, and the height is 12.5 mm.

The pile size of the carpet surface of the chenille carpet that does not use water or dyeing processing aids in the manufacturing process of the present invention is as follows.
Regarding the size of the sampled pile 1, the length is 9 mm, the width is 8.5 mm, and the height is 14 mm,
Regarding the size of the sampled pile 2, the length is 8.5 mm, the width is 8.5 mm, and the height is 13.5 mm,
Regarding the size of the sampled pile 3, the length is 9 mm, the width is 9 mm, and the height is 14 mm.

As can be seen from the above test data, the pile size on the carpet surface of the chenille carpet obtained by the present invention is larger than the pile size of the chenille carpet manufactured by conventional general-purpose processes; This shows that the shrinkage of the carpet is smaller than the shrinkage of the chenille carpet manufactured by the general-purpose process, and the bulkiness of the chenille carpet manufactured by the present invention is superior to that of the carpet manufactured by the general-purpose process.

As can be seen by combining the above two types of test items, the bulkiness of the chenille carpet manufactured by the present invention is superior to the bulkiness of the carpet manufactured by a general-purpose process.

C. Comparative test of process water usage

Yarn-dyed chenille is manufactured using general purpose process technology.
The filament yarn is 150D/144FDTY, the core yarn is polyester 16s/2, the finished chenille count is 0.45Nm, and the polyester filament fabric has a count of 300D/96FX3 and a basis weight of 270g/ ^m2. Tufting was performed using a tufting machine with a pitch of 3/8 using cloth, the hair length was 15 mm, and the pile weight of the blank carpet was 850 g/ ^m2 .
100 kg of chenille blank carpet was taken, placed in a dyeing tank, and washed with water.The washing temperature was 100°C, and the weight of water required was 800 kg.

Yarn-dyed chenille is manufactured using the manufacturing process of the present invention.

Similar to the description in Example 1, the filament is 150D/144FDTY, the core yarn is polyester 16s/2, the finished chenille count is 0.45Nm, the count is 300D/96FX3, and the basis weight is 270g/2. Tufting was performed using a tufting machine with a pitch of 3/8 using a polyester filament fabric base fabric of ^m2 , the hair length was 15 mm, and the pile weight of the blank carpet was 850 g/ ^m2. ,
Similarly, 100 kg of chenille blank carpet is taken and put into the built-in drum of the GQ-3500Z steam type forming roll machine, and subjected to high temperature friction and forming roll treatment.In the forming roll process, it is necessary to perform steam softening treatment for 20 seconds. The temperature is 100°C, the flow rate of steam is 0.13 m ³ /s, the amount of steam used is 2.6 m ³ , and the amount of water used is approximately 1.55 KG (at a temperature of 100°C, , 1 standard atmospheric pressure, and the density of water vapor is 0.59764 KG/m ³ ).

The above comparative tests show that the amount of water used in the manufacturing process of the present invention is less than that of the general process technology.

D. Comparative test of support capacity of carpet surface pile

Using general-purpose process technology, the core yarn is polyester 15S/2, the filament yarn is 150D/288FDTY, the filament width is 8mm, and the chenille yarn is produced by a spinning machine, and the finished count is 0.7Nm. Tufting was performed using a polyester filament fabric base fabric with a basis weight of 130 g/m ² and a loop pile tufting machine with a pitch of 3/8, and the tufting hair length was 30 mm. The pile weight of the blank carpet was 1350 g/m ² , and it was washed with water at 105° C. in a dyeing tank to obtain a chenille carpet.

Using the manufacturing process of the present invention and similar to the description in Example 2, the core yarn was polyester 15S/2, the filament was 150D/288FDTY, the width of the filament was 8 mm, and the spinning machine produced chenille. A thread was created, the finished count was 0.7 Nm, a polyester filament fabric base fabric with a basis weight of 130 g/m ² was used, and tufting was performed using a loop pile tufting machine with a pitch of 3/8. The hair length for tufting was 30mm, and the pile weight of the blank carpet was 1350g/ ^m2.The blank carpet after tufting was placed in the built-in drum of a GQ-3500Z steam forming roll machine and heated for 15 minutes. Rolling friction was performed, steam softening treatment was performed for 30 seconds, and the temperature was allowed to cool down naturally to obtain a chenille carpet.

Comparative test method: Take one piece of chenille carpet manufactured by two different processes, the size of which is 50 cm x 50 cm, and place it on a horizontal workbench.
2. Press a 50cm x 50cm presser plate and a 2KG weight onto the sampled carpet.
3. Measure the height from the bottom edge of the presser plate to the workbench, and the larger the value, the stronger the supporting force.

Regarding the test data, the sample mass of chenille carpet manufactured using the general-purpose process technology has a height of 19 mm from the bottom edge of the holding plate to the horizontal work platform, and the sample mass of chenille carpet manufactured using the manufacturing process of the present invention The height from the bottom edge of the holding plate to the horizontal workbench is 22 mm.

To summarize the above, the chenille carpet produced according to the present invention has a stronger pile support on the carpet surface.

E. Comparative test of the amount of chemical aids used in dyeing treatment

A yarn-dyed camel-colored chenille carpet is manufactured using a general-purpose process technology, and a yarn-dyed camel-colored chenille carpet is manufactured using the manufacturing process of the present invention.

General purpose process technology produces yarn-dyed chenille carpet through a water washing process.

The chenille filament is 150D/144FDTY, the core yarn is polyester 16s/2, the finished chenille count is 0.45Nm, the count is 300D/96FX3, and the basis weight is polyester filament fabric with a basis weight of 270g/ ^m2 . Tufting was performed using a tufting machine with a pitch of 3/8, the hair length was 15 mm, and the pile weight of the blank carpet was 850 g/m ² , and then 50 kg of blank carpet was taken. Put it in a dyeing tank, the bath ratio is 1:10, add 500KG of water to the rapid dyeing machine, heat it up to 100℃, wash it with water, add 5KG of softener to soften it, and then After dewatering, drying and finishing, a chenille carpet was obtained.

The manufacturing process of the present invention produces yarn-dyed chenille carpet by forming roll processing.

Similar to Example 1, the chenille filament is 150D/144FDTY, the core yarn is polyester 16s/2, the finished chenille count is 0.45Nm, the count is 300D/96FX3, and the basis weight is 270g/m Tufting was performed using a tufting machine with a pitch of 3/8 using the polyester filament fabric base fabric of No. ² , the hair length was 15 mm, and the pile weight of the blank carpet was 850 g/m ² . Take 50 kg of carpet and put it into the built-in drum of GQ-3500Z steam type forming roll machine, set the rotation speed of the built-in drum of the forming roll machine to 18 r/min, set the heating temperature of the forming roll machine to 100°C, and set the heating rolling time. for 7 minutes, forward and reverse rotation times for 3.5 minutes each, steam softening treatment, steam temperature of 100°C, steam release time of 20 s, steam and heating module turned off, and natural cooling. The temperature was lowered to 70° C. and the cooling time was 5 minutes, followed by finishing to obtain a chenille carpet.

As can be seen by comparing the chenille carpet obtained by the conventional process technique and the manufacturing process of the present invention, the chenille carpet obtained by the present invention is free of dyeing aids such as softeners.

The preferred embodiments of the present invention have been described above in detail. As will be understood by those skilled in the art, the present invention is not limited to the embodiments described above, and the embodiments and specification described above are merely illustrative of the principles of the invention, and the present invention is not limited to the embodiments described above. The present invention may further include various modifications and improvements without departing from the spirit and scope of the invention, and all such modifications and improvements are included within the protection scope of the present invention. The scope of protection of the present invention is subject to the appended claims.

Claims (17)

Including a carpet surface layer and a base fabric layer,
The base layer includes a synthetic fiber knit or fabric base layer, a composite base layer formed of a synthetic fiber knit or fabric and/or a needle punched synthetic nonwoven fabric, or a spunbond nonwoven fabric base layer, and the carpet surface layer is made of chenille. After performing tufting processing on the base fabric layer using yarn, the carpet layer includes a loop pile layer formed on one side of the base fabric layer, and further processing forms a carpet surface layer having a particle shape. Chenille carpet. The carpet further includes a bottom backing layer, and the bottom backing layer includes a non-slip treated layer comprising a hot melt adhesive, a thermoplastic elastomer, a foamed latex, or a composite of fabrics and materials with a non-slip function. The chenille carpet according to item 1. The tufting layer is heated and rolled, softened, cooled and cooled to form a loop pile of the tufted layer into a granular pile, and the height of the loop pile of the tufting layer is 3.5 mm to 45 mm. The chenille carpet according to claim 1, characterized in that: The base fabric layer is a composite base fabric layer, made of needle-punched synthetic fiber nonwoven fabric, and has a weight of 50 to 500 g/m ² , or
The base fabric layer is a composite base fabric layer, made of synthetic fiber knit or fabric, and has a weight of 70 to 350 g/ ^m2 , or
The base layer is a knit or fabric base layer, and has a weight of 50 to 350 g/m ² , or
The chenille carpet according to claim 1, wherein the base fabric layer is a spunbond nonwoven fabric base layer and has a weight of 50 to 350 g/m ² . The raw material of the base fabric layer includes one or more of chemical fibers, natural fibers, and blended fibers,
The chenille yarn of the carpet surface layer has two strands woven from short fibers or filaments of different finenesses as core yarns, and by twisting them with different twist degrees, the filaments of different finenesses are cut into different widths. It is woven by sandwiching it between the core threads of a book,
The chenille carpet according to claim 1, wherein the material of the chenille yarn includes one or more of polyester, nylon, cotton, and blended fibers. The chenille yarn has a count of 2.6Nm to 0.2Nm, a twist of 280T/M to 800T/M, a filament count of 30D to 600D, and a filament width of 2mm to 15mm. The chenille carpet according to claim 5, characterized in that: S1: After performing tufting on the base fabric layer using chenille yarn, forming a carpet surface layer on one side of the base fabric layer to produce a blank carpet;
A method for manufacturing a chenille carpet, comprising the steps of S2: treating the blank carpet to form loop piles of the carpet surface layer into particulate piles. processing the blank carpet to form a loop pile of the carpet surface layer into a granular pile;
The blank carpet is placed in a forming roll machine, heated and rolled, reversed, softened, cooled and cooled to form a loop pile of the carpet surface layer into a granular pile,
The types of forming roll machines include steam-type forming roll machines, electrically heated and heat-conducting oil-type forming roll machines, or natural gas-heated oil-type forming roll machines;
The forming roll machine has a built-in rolling housing, and a plurality of heat radiation holes are distributed on the housing wall of the rolling housing, and the built-in rolling housing of the forming roll machine has normal rotation and reverse rotation. The rotation speed can be set as constant speed or frequency conversion control as necessary, the rolling speed can be varied in the range of 10r/min to 30r/min, and the forward rotation time or reverse rotation time can be set as necessary. The speed is 5 min to 120 min, and the forward and reverse directions can be automatically cycled and switched evenly.
The blank carpet is in a naturally unraveled state in the rolling housing, and in the process of the blank carpet rotating with the rolling housing, the blank carpet reaches a certain height on the inner wall of the housing. 8. The method of manufacturing a chenille carpet according to claim 7, wherein the process is repeated in a circular manner so that the carpet is rotated and then freely falls to start the next rotation. The temperature setting range in the heating and rolling process of the forming roll machine is 70°C to 200°C, the softening treatment time is 5s to 600s, the heating program is turned off during the cooling and cooling process, and the blower is used to cool the blank carpet by internal circulation. Claim 8, wherein the temperature is naturally lowered and the built-in casing of the forming roll machine continues to operate so as to automatically and uniformly cycle and change the rotation direction during the temperature-lowering process until the temperature-lowering program is completed. The method for manufacturing chenille carpet described in . processing the blank carpet to form a loop pile of the carpet surface layer into a granular pile;
In order to form a loop pile of the carpet surface layer into a granular pile, the blank carpet is placed in a molding machine, and is blown by the blower of the molding machine, and then the blank carpet is moved into an S-shaped air path inside the molding machine by wind force. 8. The chenille carpet according to claim 7, further comprising shaking and heating drying the blank carpet using a dryer, and applying high frequency friction between the carpet and the S-shaped air passage while shaking the carpet. Production method. The shaping machine includes a shaker drying shaping machine,
The type of shaker drying machine includes any one of a steam type shaker drying type machine, an electric heating/thermal conduction oil type shaker drying type machine, and a natural gas heating oil type shaker drying type machine,
The first half of the shaker drying machine is an S-shaped curved wind duct unit, and the second half is a mesh belt type conveying unit, and the shaker drying machine has two or more powerful blowers, and the shaker drying machine has two or more powerful blowers. 11. The method for manufacturing chenille carpet according to claim 10, wherein the machine blows air with a blower to generate wind power, and further advances the blank into a mold machine. The chenille carpet manufacturing method according to claim 10, wherein the temperature control range of the shaker dryer is 100° C. to 200° C., and the operating speed is 0.5 m/min to 10 m/min. processing the blank carpet to form a loop pile of the carpet surface layer into a granular pile;
placing the blank carpet in a dryer, heating and rolling the blank carpet in the dryer to dry it, forming a loop pile of the carpet surface layer into a particulate pile;
The dryer has a built-in drum, a plurality of heat radiation holes are distributed on the drum wall, the weight of the blank carpet that can be stored in the dryer is 15KG to 250KG, and the rotation speed of the dryer drum is 29r/min to 250KG. The method for manufacturing a chenille carpet according to claim 7, wherein the heating rate is 35 r/min and the heating temperature is 70°C to 180°C. processing the blank carpet to form a loop pile of the carpet surface layer into a granular pile;
2. The method of claim 1, further comprising placing the blank carpet into a built-in drum of a GQ-3500Z steam forming roll machine and subjecting it to high-temperature friction and forming roll treatment to form the loop pile of the carpet surface layer into a granular pile. 7. The method for producing a chenille carpet according to 7. The method for manufacturing chenille carpet according to any one of claims 7 to 14, characterized in that all operations in step S2 are carried out manually or by an automatic program to achieve continuous operation. After completing step S2, the method further includes spraying a softener hydraulic fluid onto the carpet surface, wherein the softener hydraulic fluid has a softener content of 5 g/L to 40 g/L, and the softener hydraulic fluid is used. The method for producing chenille carpet according to any one of claims 7 to 14, characterized in that the amount is 50 g/m ² -200 g/m ² . The carpet obtained in step S2 is subjected to a bottom coating process, that is, the bottom of the carpet is coated with hot melt adhesive, thermoplastic elastomer, foam adhesive, or other single backing material or backing with anti-slip treatment. Composite siding and/or
The method for producing a chenille carpet according to any one of claims 7 to 14, further comprising subjecting the obtained chenille carpet to secondary processing including printing.